Combined optimization of part topology, support structure layout and build orientation for additive manufacturing

Langelaar, Matthijs

doi:10.1007/s00158-017-1877-z

Combined optimization of part topology, support structure layout and build orientation for additive manufacturing

Title

Combined optimization of part topology, support structure layout and build orientation for additive manufacturing

Author

Langelaar, Matthijs (TU Delft Computational Design and Mechanics)

Date

2018

Abstract

Additive manufacturing (AM) enables the fabrication of parts of unprecedented complexity. Dedicated topology optimization approaches, that account for specific AM restrictions, are instrumental in fully exploiting this capability. In popular powder-bed-based AM processes, the critical overhang angle of downward facing surfaces limits printability of parts. This can be addressed by changing build orientation, part adaptation, or addition of sacrificial support structures. Thus far, each of these measures have been studied separately and applied sequentially, which leads to suboptimal solutions or excessive computation cost. This paper presents and studies, based on 2D test problems, an approach enabling simultaneous optimization of part geometry, support layout and build orientation. This allows designers to find a rational tradeoff between manufacturing cost and part performance. The relative computational cost of the approach is modest, and in numerical tests it consistently obtains high quality solutions.

Subject

Additive manufacturing
Build orientation
Design for manufacturing
Overhang angle
Printing direction
Support structures
Topology optimization

To reference this document use:

http://resolver.tudelft.nl/uuid:957510d2-5971-49b7-a7d6-78e3823e9bf4

DOI

https://doi.org/10.1007/s00158-017-1877-z

ISSN

1615-147X

Source

Structural and Multidisciplinary Optimization, 57 (5), 1985-2004

Part of collection

Institutional Repository